Rotary screw air compressors are the most simple to design and maintain of all the air compressors on the market. They have a long service life and are relatively easy to maintain. As a result, rotary screw air compressors are used in businesses of all sizes, from large corporations to one-person shops. A rotary air compressor, when properly maintained, can operate for thousands of hours without interruption.
Why Regular Maintenance of Your Rotary Screw Compressor Is Important
Rotary screw compressors, like all other types of compressors, need to be serviced on a regular basis. Maintenance on most rotary air compressors is relatively simple thanks to the simplicity of the internal components. As long as you stick to a rotary screw compressor maintenance schedule, you will likely be rewarded with many, many years of optimal productivity from your machine.
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Save Time and Money
When you stick to a screw compressor maintenance schedule, you lessen the risk of unexpected system downtime. You can spot potential problems early on, before they get out of hand and turn into more serious problems, with routine checkups. The sooner you recognize a problem, the easier and less expensive it is to fix it. In many cases, a problem that is detected early on can be resolved in a short amount of time with no cost.
In the long run, routine maintenance saves time. System downtime is costly and time-consuming in any industry. The time a compressor is down and inoperable is time lost in terms of productivity. Even a few hours of downtime can cost you a lot of money.
. With regular air compressor maintenance, you lower the risk of costly downtime.
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Increase the Life Expectancy of Assets
A big advantage of preventive maintenance is that it can help you extend the life of your equipment. When it comes to maintenance, equipment replacement can provoke potential disruptions to your operations and finances. Replacing your air compressor is sometimes an inevitable reality. All of them will age and eventually need replacing.
Preventive maintenance is one of the very best ways to increase your assets’ life expectancy. Keeping your air compressors well-lubricated, changing their filters and fixing small issues as needed can help your systems run smoothly for a long time.
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Improve Workplace Safety
Maintaining your air compressor can enhance workplace safety. For one, an unexpected equipment failure can pose a safety hazard since it may lead to other types of machinery malfunctioning or stopping suddenly. Maintenance routines can avoid problems with your equipment that can put at risk your employees health and safety. Carrying out regular upkeep of all your equipment, including your air compressors, can reduce health and safety incidents.
A Guide to Rotary Screw Maintenance Tasks
Rotary screw air compressors are designed to withstand years of heavy use. Air compressors, on the other hand, have their limits and must be inspected on a regular basis to ensure optimal performance for the duration of their service life.
A rotary air compressor has several key internal components that can wear out over time if they aren't inspected on a regular basis. The airend and drive train are the most important of these components, as they pressurize the air and drive the air compressor's mechanisms. It's also crucial to inspect the motor and filters on a regular basis, as well as replace the lubricants as needed.
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Airends: The airend, or the screw element, is the heart of any rotary screw compressor: This is where the actual compression takes place. Airends can be damaged by excessive heat, contamination in the air and even dirty rotary screw compressor fluid. Your preventive maintenance procedure should include regular airend inspections — excessive noise and vibration can also be a telltale sign of an airend issue.
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Drive train: Check the rotary compressor’s drive train to ensure it is properly aligned and that the gear drives are properly lubricated. The tension of V-belt drives should be adjusted approximately every 500 hours. Immediately replace frayed or worn belts.
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Motor: Keep the motor bearings properly lubricated and replace them before they wear out. Also monitor the ampere draw to minimize the likelihood of overloading. Maintaining sufficient ventilation in the compressor room or operating environment can go a long way toward maximizing the motor’s lifespan.
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Filters: One of the easiest and most cost-effective ways to prevent premature wear is to replace your rotary compressor’s filters on a regular basis, as this will reduce airend wear and component contamination. Replacement of air inlet filters is recommended every two thousand hours, and you should change the fluid filters every one thousand hours.
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Lubricants: Lubricants perform the vital functions of removing contaminants, protecting moving parts from excess wear and keeping the compressor cool. The best advice regarding when to change rotary screw compressor fluid is to adhere to the manufacturer’s recommended schedule. Regular oil sampling can help to lengthen the lubricant’s lifespan, and can affect warranty compliance in some cases.
Keeping the rotary screw air compressor as clean as possible is another general rotary screw air compressor maintenance tip. Dirt and debris can cause the temperature of compressed air to rise, in addition to causing damage to compressor components. Also, avoid running the compressor for long periods of time at high temperatures.
How Often Should You Maintain Your Rotary Screw Compressor?
Changes in the compressor are likely to occur over the course of 3,000 hours of use, altering certain settings to the detriment of your system's health.
Daily Maintenance
At the end of each working day, check the control panel displays on your air compressor to ensure that the readings are normal. Also make sure that the gauges are properly set according to the specifications of your make and model. As a guide for these inspections, refer back to the records of previous days and months to ensure that the measurements remain consistent over time.
Perform these observations for each mode of operation, regardless of whether or not you run the machine at full load. If the readings begin to deviate from the records despite a lack of adjustments, it is time to inspect your air compressor.
Quarterly and Biannual Maintenance
After every 1,000 to 3,000 hours of operation, the filters of your air compressor should be inspected and serviced as necessary. For best results, stick to the screw compressor maintenance checklist included in your instruction manual. Intervals vary greatly from unit to unit:
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Daily Inspections
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Quarterly Service
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Annual Service
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Major Overhaul
On a weekly basis, inspect the condensate drain and clean if necessary. Also take record of the readings on the compressor, motor and gearbox. Refer back to the user’s manual of your air compressor to ensure that the settings and readings remain consistent with the recommendations of the manufacturer.
Call All Air Compressors for Preventative Maintenance for Your Air Compressor System
All Air Compressors is a compressed air service and repair company that also installs air piping and line filters. Throughout NSW, our mobile technicians are available for scheduled maintenance as well as 24-hour breakdowns and repairs.
We’re ready to help you make sure your air compressor and your entire compressed air system are working as well as possible, so you can keep your operations running efficiently. To schedule regular air compressor maintenance — please contact us today.